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Abstract:

A repairable synthetic turf field having a plurality of phases of use and
a method for revitalizing the same, the repairable synthetic turf
including a plurality of synthetic fibers extending from a backing and
having an infill interspersed between the synthetic fibers, the synthetic
fibers having a portion extending above the infill forming a first field
surface during a first phase of use, wherein at least a part of the
portion of the synthetic fibers extending above the infill may be removed
creating a second phase of use wherein a new portion of the synthetic
fibers extends above the infill forming a second field surface.

Claims:

1. A method of revitalizing a synthetic turf field having a plurality of
synthetic fibers, each fiber extending vertically from a backing, the
turf including an infill interspersed between the plurality of fibers
such that a portion of the fibers extend above the infill, the method
comprising the step of: removing at least a part of the portion of the
fibers extending above the infill.

2. The method of claim 1 further comprising the step of displacing at
least a portion of the infill.

3. The method of claim 2 further comprising the step of removing at least
a portion of the infill when displacing at least a portion of the infill.

4. The method of claim 3 further comprising the step of removing all of
the infill when removing at least a portion of the infill.

5. The method of claim 3 further comprising the step of disposing of at
least a portion of the removed infill.

6. The method of claim 3 further comprising the step of recycling at
least a portion of the removed infill.

7. The method of claim 3 further comprising the step of reinserting at
least a portion of the removed infill.

8. The method of claim 7 further comprising the step of cleansing the
removed infill before reinserting at least a portion of the removed
infill.

9. The method of claim 8 further comprising the step of sifting a
particulate material forming the infill before reinserting at least a
portion of the removed infill.

10. The method of claim 3 further comprising the step of replacing at
least a portion of the removed infill with new infill.

11. The method of claim 10 further comprising the step of layering at
least two different types of particulate material when replacing at least
a portion of the removed infill with new infill.

12. The method of claim 3 further comprising the step of replacing the
removed infill in a manner such that a surface hardness of the synthetic
turf field after revitalization is substantially equal to an initial
surface hardness of the synthetic turf field at the time of installation.

13. The method of claim 1 further comprising the step of removing a
substantially uniform part from a portion of each fiber in the plurality
of fibers extending above the infill.

14. The method of claim 1 further comprising the step of removing an
additional part of the fibers surrounded by the infill.

15. The method of claim 13 further comprising the step of removing a
substantially similar amount from each fiber.

16. The method of claim 1 further comprising the step of mowing the at
least a part of the portion of fibers extending above the infill.

17. The method of claim 1 further comprising the step of shearing the at
least a part of the portion of fibers extending above the infill.

18. The method of claim 1 further comprising the step of cutting the at
least a part of the portion of fibers extending above the infill.

19. The method of claim 17 further comprising the step of utilizing
suction when cutting the at least a portion of the fibers extending above
the infill.

20. A repairable synthetic turf field capable of a plurality of phases of
use, the field comprising: a backing; a plurality of synthetic turf
fibers having a first length and extending vertically from the backing
during a first phase of use; an infill interspersed between the plurality
of fibers, the infill having a depth less than the first length of the
plurality fibers, the infill providing a surface hardness during the
first phase of use; wherein the plurality of synthetic fibers and the
infill are capable of a second phase of use wherein the plurality of
synthetic fibers are modified to have a second length and extend
vertically a second distance from the backing, wherein the infill is
capable of being modified to have a depth less than the second length of
the plurality of synthetic turf fibers while substantially maintaining
the surface hardness.

21. A repairable synthetic turf field capable of a plurality of phases of
use, the field comprising: a backing; a plurality of synthetic turf
fibers extending vertically from the backing; an infill interspersed
between the plurality of fibers such that a first portion of the
plurality of fibers extend above the infill forming a first field
surface, the infill providing a surface hardness for the synthetic turf
field, wherein the plurality of synthetic fibers and the infill are
capable of modification for at least a second phase of use wherein a
second portion of the synthetic fibers extend above the infill while the
infill maintains the surface hardness of the synthetic turf field.

Description:

RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application
No. 61/476,607 filed Apr. 18, 2011, the contents of which is fully
incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention is related to synthetic turf fields and more
particularly to a repairable synthetic turf field and a method for
revitalizing such a field as a result of damage over time.

BACKGROUND OF THE INVENTION

[0003] Modern synthetic turf fields typically include a plurality of
synthetic fibers or ribbons extending vertically from a backing, and an
infill interspersed between the synthetic fibers. The synthetic fibers
typically contain an exposed portion that extends above the infill
mimicking grass or the like. This exposed portion of the fibers provides
at least a portion of the field surface and is directly exposed to
weather elements and contact from individuals or objects traversing the
field.

[0004] Over time, in some synthetic turf fields, the exposed portion of
the fibers may become damaged. This damage may be caused by things such
as ordinary wear and tear, excessive or improper use of the field,
exposure to extreme or unusual weather conditions, from the use of lower
quality or improper materials, from improper or lack of maintenance on
the field, from exposure to improper chemicals, or from acts of
vandalism. The damage resulting from any of the aforementioned or other
causes may include things such as the exposed portions of the fibers:
splitting longitudinally or fraying, becoming discolored, weakening or
degrading, shearing and/or severing, among other adverse or aesthetically
unpleasing characteristics. Regardless of the type of damage, or cause
thereof occurring at or near the exposed portions of the fibers,
currently there is no viable solution to repair or rejuvenate same short
of complete removal of affected areas and/or removal and replacement of
the total turf field.

[0005] The present invention is directed to solving these and other
problems.

SUMMARY OF THE INVENTION

[0006] The present invention is directed to providing a synthetic turf
field capable of revitalization and a method for accomplishing the same.
According to one aspect of the invention, a synthetic turf field having a
plurality of synthetic fibers extending vertically from a backing is
provided. The synthetic turf includes an infill interspersed between the
plurality of synthetic fibers in a manner such that a portion of the
plurality of synthetic fibers extends above the infill. This portion of
the fibers extending above the infill forms, at least in part, a field
surface which may be traversed by people or objects during use of the
field. In order to provide the possibility of repair and/or
revitalization of the field, the plurality of synthetic turf fibers are
configured such that if the portions forming the field surface become
damaged in any manner for any reason, like for example becoming frayed or
split from excessive or improper use, the damaged portions may be removed
from the fibers and a new field surface may be created from a second
portion of the plurality of synthetic fibers that have been protected
from damage by the infill.

[0007] According to another aspect of the invention, the portions of the
plurality of synthetic fibers extending above the infill may be removed
to revitalize the field using any technique, like, for example, mowing as
is customarily done on natural grass surfaces, shearing, cutting, flexing
and breaking, or chemically. No matter the method of removal, though not
required, it is advantageous to remove a substantially similar
amount/length from each fiber in the plurality of fibers to maintain the
uniform field surface characteristics. As should be appreciated by those
having ordinary skill in the art, in addition to removing a portion of
the fibers extending above the infill, for some fields it may be
advantageous, or even necessary, to remove a portion of the plurality of
fibers surrounded or covered by the infill. According to one aspect of
the invention, any amount of the fibers may be removed so long as the
field maintains a substantially similar playability, and the fibers have
sufficient length to extend vertically a sufficient distance above an
amount of infill required to maintain a substantially constant GMAX
rating or other surface hardness, or return the GMAX rating or other
surface hardness to a level substantially equal to that of when the field
was initially installed, or to any other satisfactory hardness level.

[0008] According to yet another aspect of the invention, in order
facilitate the revitalization of the field and the removal of the
portions of the synthetic fibers forming the field surface, the synthetic
fibers may include a geometry or characteristic to enhance the
removability of at least a part of the portions extending above the
infill. For example, each synthetic turf fiber may include a horizontal
groove or channel having a thickness less than the remainder of the
fiber, or each synthetic turf fiber may contain a portion responsive to a
chemical or temperature in a manner which weakens the fiber at that
point. In synthetic fields having fibers capable of multiple portions
removed, two or more areas on the fibers may be provided with the
geometry or characteristic. As should be appreciated by those having
ordinary skill in the art, in fibers where a geometry or characteristic
is used to facilitate removal, it is particularly advantageous to place
any such areas on the fibers below the top of the initially installed
infill, i.e. do not extend above the infill and form part of the field
surface, so as to guard against accidental cutting or shearing during
ordinary use of the field and prevent exposure to chemicals or
temperatures which may otherwise react with the fibers. Where multiple
areas are included in each fiber, the areas having the geometry or
chemical should be spaced apart so as to allow for a new field surface to
be created while the remaining areas having the geometry or
characteristic are surrounded or covered by the infill.

[0009] According to still another aspect of the invention, in order to
facilitate the revitalization of the field and the removal of the
portions of the synthetic fibers forming the field surface, at least a
portion of the infill may be displaced and/or removed. After
displacement/removal of the infill and the portions of the fibers forming
field surface have been removed, the infill may be replaced in the area
it was displaced from. Any infill that is replaced should be replaced at
a depth such that a portion of the plurality of synthetic fibers extends
above the infill after the previous portion forming the field surface is
removed. Preferably the infill should further be replaced in a manner
which creates a GMAX rating or surface hardness substantially equal to
that of the field before revitalization or when the field was installed.
As should be appreciated by those having ordinary skill in the art, these
"new" portions extending above the infill form a second "new" field
surface by utilizing previously unexposed and/or different and undamaged
portion of the fibers.

[0010] According to yet another aspect of the invention, in order to
facilitate the revitalization of the field and the removal of the
portions of the synthetic fibers forming the field surface, a portion or
all of the infill may be removed from the field entirely. Once the infill
is removed it may be disposed of, recycled, or reinserted into the field.
Infill that is recycled, like for example reused in a different field, or
reinserted into the field the infill was removed from, may first be
washed, cleansed, sifted, or otherwise cleaned and/or disinfected before
being reused or reinserted.

[0011] Regardless of whether new infill is used to replace disposed of
infill, or a portion or all of the previously used infill is reinserted
after the portions of the fibers previously extending above the infill
are removed, the infill should be replaced or reinserted at a depth less
than the height/length of the plurality of remaining portions of the
synthetic fibers so as to maintain or recreate the field at a desired
GMAX rating or surface hardness, or restoring the GMAX rating or surface
hardness to a substantially similar level as when the field was initially
installed.

[0012] Other aspects and features of the invention will become apparent to
those having ordinarily skill in the art upon review of the following
Description, Claims, and associated Drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 shows a cross-section of an artificial turf field during a
first phase of use as contemplated by this invention.

[0014] FIG. 2 shows a cross-section of an artificial turf field during a
second phase of use after revitalization as contemplated by this
invention.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0015] While the present invention is susceptible of embodiment in many
different forms, there is shown in the drawings and will herein be
described in detail, preferred embodiments of the invention with the
understanding that the present disclosure is to be considered as an
exemplification of the principles of the invention and is not intended to
limit the broad aspect of the invention to the embodiments illustrated.

[0016] FIG. 1 shows a cross-section of a synthetic turf field during a
first phase of use as contemplated by the invention. Synthetic turf field
10 includes a plurality of synthetic fibers 12 having a length L and
extending vertically from a backing 14. Interspersed between fibers 12 is
infill 16, having a depth D, which as seen in FIG. 1 is some amount less
than length L.

[0017] As seen in FIG. 1, each fiber 12 includes a portion P extending
above, and preferably covering, the infill 16. The collective of each
portion P forms a field surface that may be traversed by individuals or
objects and is exposed to the environment. For example, in a preferred
embodiment, length L is substantially equal to 3.25 inches and portion P
is substantially equal to about 0.75 inches, making depth D substantially
equal to about 2.5 inches.

[0018] Fibers 12, including portions P, may be colored to indicate for
example, boundaries or areas of play for a particular sport or multiple
sports, and/or to indicate a particular team through name, location, or
mascot. Fibers 12 and portions P may be made of any material which
achieves a desired stiffness or resiliency for a particular usage, and
include fibers made from different or multiple materials to achieve a
desired effect and playing characteristics.

[0019] Amongst the other known uses, infill 16 provides support and
stability for fibers 12, and provides field 10 with a desired surface
hardness, sometimes referred to as a GMAX rating. In some embodiments,
infill 16 may include multiple layers of different particulate material.

[0020] FIG. 2 shows a cross-section of field 10 during a second phase of
use, after the revitalization of field 10 has been completed. After
revitalization and during the second phase of use, field 10 contains
fibers 12 having a length L' and extending vertically from backing 14.
Field 10 after revitalization still includes an infill 16 interspersed
between fibers 12, infill 16 having a depth D'. A portion P' of each
fiber 12 extends above infill 16, forming a "new" playing surface for
field 10 during the second phase of use. Though not drawn to scale, as
seen in the FIGs., it should be appreciated that in a preferred
embodiment of the invention, length L'<length L and depth D'<depth
D. Though depth D' may be less than depth D after field 10 has been
revitalized, the surface hardness or GMAX rating supplied by infill 16
for field 10 should remain substantially constant, i.e. the surface
hardness or GMAX rating of phase two of field 10 should be substantially
equal to either or both: the surface hardness or GMAX rating at the time
of revitalization, or the surface hardness or GMAX rating at the
beginning of phase one of field 10, i.e. when field 10 was initially
installed.

[0021] In order to revitalize field 10 and move field 10 from the first
phase of use to the second phase of use, portions R of each fiber are
removed--this removal is indicated by the dashed portions R of fibers 12
in FIG. 2. The amount of portion R that is removed from fibers 12 may
vary depending on the damage to each fiber 12, i.e. how far each fiber 12
has split or frayed in the vertical direction, or how far down along the
length of the fiber discoloration or other damage has occurred.

[0022] In a preferred embodiment of the invention, portion R may be less
than or substantially equal to portion P. Inasmuch as revitalizing field
10 may only require removing and "replacing" portions P extending above
infill 16 which form the field surface, removing part or all of portion P
of each fiber will generally provide satisfactory portions P' for a "new"
field surface. However, it is contemplated by the invention that in some
embodiments, in addition to portion P, portion R may include a portion of
fiber 12 surrounded and/or covered by infill 16.

[0023] Whether portion R is less than or equal to portion P, or portion R
includes portion P and an additional part of fiber 12 that is surrounded
and/or covered by infill 16, it is contemplated by the invention that
whether or not portion R of every fiber 12 is damaged, a substantially
uniform portion R may be removed from each fiber 12. Removing a
substantially similar portion R from each fiber 12 insures that the field
surface of field 10 during the second phase of use substantially matches
the field surface during the first phase of use.

[0024] Removing portions R from fibers 12 may be accomplished using any
means known in the art. For example, portions R may be removed by mowing
fibers 12 in a manner substantially similar to the manner a natural grass
field would be mowed. As with natural grass mowing, a mower used to mow
field 10 may be set to insure that fibers 12 are length L' after mowing
is completed. It is also contemplated by the invention that portions R
may be cut or sheared from fibers 12, and that any cutting or shearing
device may include a suction or vacuum like structure to fully straighten
fibers 12 to insure only portion R is removed.

[0025] In order to facilitate the removal of portion R, achieve depth D'
of infill 16, insure that L'<D', and perhaps further revitalize field
10, at any time before, during, or after the process of removing portion
R, a portion of infill 16 may be displaced, by, for example, moving or
re-locating portions of infill 16 to other areas of field 10, or by
removing a portion of or all of infill 16 from field 10 either
temporarily or permanently. While removal may be unnecessary when
revitalizing some fields, like for example if portion R is less than
portion P or infill 16 is compacted to a level where depth D is now
substantially less than portion R or may be substantially equal to a
desired D', at least a portion of infill 16 may be removed to, for
example, redistribute infill that has moved or migrated in field 10,
loosen infill to reestablish a surface hardness or GMAX rating, re-layer
infill if the infill contains multiple layers of different particulate
material, or to avoid infill from being collected with the removed
portions R of fibers 12.

[0026] In embodiments where a portion or all of infill 16 is removed from
field 10, it is contemplated that the removed portion of infill 16 may be
disposed of entirely, may be recycled or reused in other synthetic turf
fields, or may be reinserted into field 10. It is contemplated by the
invention that before reuse or reinsertion of any removed infill, the
infill materials may be washed or cleansed to remove any unwanted dirt or
debris from the removed infill prior to re-use.

[0027] In fields where infill 16 contains multiple layers of different
particulate material, infill 16 may be removed layer-by-layer or
alternatively sifted or otherwise separated to separate the particulate
materials before reuse or reinsertion. If the removed infill is to be
reinserted into field 10 after sifting, the removed infill may be
reinserted in a layered manner substantially similar to that before the
infill's removal.

[0028] For example, in a field having a layer of sand beneath a layer of
rubber in the infill, the layer of rubber may be removed first, and then
the layer of sand may be removed separately. If removal of a portion of
the infill results in both sand and rubber being removed, or if an infill
containing multiple layers of particulate material is removed in a single
removal process, then the sand and rubber may be sifted and separated,
and a desired amount of removed sand reinserted into infill 16 followed
by reinsertion of a desired amount of removed rubber may be achieved.

[0029] Regardless of whether any infill is removed or any infill is
disposed of, reused at a different artificial turf field, completely or
partially recycled or reinserted into field 10, as should be appreciated
by those having skill in the art, infill 16 may include newly introduced
infill. As with reinserted infill, any new infill placed into field 10
may be layered in a substantially same manner as infill 16 was during the
first phase of use before field 10 was revitalized.

[0030] No matter if infill is displaced or removed, in a preferred
embodiment of the invention after revitalization portions P' should
extend approximately 0.75 inches above infill 16, i.e. length L' should
be approximately 0.75 inches greater than depth D', and field 10 should
have a substantially identical surface hardness or GMAX rating to field
10 before revitalization or at the time of installation, i.e. at the
beginning of phase one. Alternatively, if a new surface hardness or GMAX
rating is desired, infill 16 may be modified to match the newly desired
requirements. Whether attempting to maintain a constant surface hardness
or GMAX rating or achieve a newly desired level, a level of surface
hardness or GMAX rating may be achieved by introducing new and/or
different infill compositions, loosening or replacing existing infill not
removed from field 10 during revitalization, or reinserting more or less
of the infill removed from field 10 during the revitalization process.

[0031] The above-described embodiments of the present invention are
intended to be examples only. Alterations, modifications and variations
may be affected to the particular embodiments by those of skill in the
art without departing from the scope of the invention, which is defined
by the claims appended hereto.